Detection Method and Hair Planting Apparatus

The present application claims the benefit of priority of Japanese Patent Application No. 2024-165741, filed on Sep. 25, 2024, the content of which is incorporated herein by reference.

The present invention relates to a detection method of detecting hair for planting planted on a mesh of a mesh-like base material and a hair planting apparatus.

In order to manufacture a wig or a hairpiece, a hair planting apparatus of the related art for planting hair for planting to a base material includes a base holding mechanism for holding a mesh-like base material, and a plurality of capture mechanisms for capturing hair for planting with a hook needle and knotting it to the base material (see, for example, JP2020-133073A).

In the hair planting apparatus of the related art, a camera is mounted to capture an image of the base material and to specify a mesh on which hair planting is performed by the capture mechanism.

There is a demand to apply the camera to capture an image of the base material after hair planting and to confirm whether hair planting has been properly performed.

In this case, a method is considered in which a captured image of the mesh of the base material before hair planting is compared with a captured image of the mesh of the base material after hair planting.

However, the mesh-like base material is generally flexible, and the position, shape, posture, or the like of the target mesh is likely to change before and after hair planting, making it difficult to maintain a certain level of accuracy in determination by image comparison.

An object of the present invention is to determine a state of hair planted on a mesh of a base material with higher accuracy than in the related art.

a detection method of detecting hair for planting planted on a mesh of a mesh-like base material, the detection method including: image acquisition of acquiring a pre-image of the mesh targeted for hair planting of the base material captured before hair planting and a post-image thereof captured after hair planting, transformation matrix acquisition of acquiring a posture transformation matrix of the mesh from the pre-image and the post-image, acquiring a difference image between a transformed pre-image and the post-image, the transformed pre-image being obtained by transforming the pre-image with the posture transformation matrix, and hair detection of specifying the presence or absence or a hair planting position of hair for planting with respect to the mesh from the difference image. The present invention provides

a base support mechanism configured to support a mesh-like base material, a hair planting unit configured to knot the hair for planting held by the hair holding mechanism to the base material using a hook needle, an imaging unit configured to capture a position where the hair planting unit performs a hair planting operation on the base material supported by the base support mechanism, an image acquisition processing unit configured to acquire a pre-image of a mesh targeted for hair planting of the base material captured before hair planting and a post-image thereof captured after hair planting, a transformation matrix acquisition processing unit configured to acquire a posture transformation matrix of the mesh from the pre-image and the post-image, a difference processing unit configured to acquire a difference image between a transformed pre-image and the post-image, the transformed pre-image being obtained by transforming the pre-image with the posture transformation matrix, and a hair-for-planting detection processing unit configured to specify the presence or absence or a hair planting position of hair for planting with respect to the mesh from the difference image. Another invention provides a hair planting apparatus including:

By the above configuration, the state of hair planted on the mesh of the base material can be determined with higher accuracy than in the related art.

10 Hereinafter, a hair planting apparatusaccording to an embodiment of the present invention will be described in detail with reference to the drawings.

1 FIG. 2 FIG. 3 5 FIGS.to 10 10 is a front view showing a schematic configuration of a hair planting apparatus,is a block diagram showing its control system, andare perspective views of the hair planting apparatusviewed from different directions, respectively.

10 The hair planting apparatusis intended to reduce workload and to smoothly plant a hair for planting M into a base material J in order to manufacture a wig or hairpiece.

The hair for planting M is not limited to human hair, but is intended for all other fibers comparable to human hair, including natural fibers and artificial fibers.

The base material J is not limited to a fiber shape and includes all sheet-like materials having a planar or curved shape, but in the present embodiment, a sheet having a curved shape (approximately a spherical shell shape) that has hexagonal lattice-like mesh holes and imitates the shape of the crown of the human head will be exemplified. Note that the shape of the mesh hole need not be hexagonal.

10 30 40 50 30 68 30 74 68 21 68 1 24 22 2 23 1 2 25 211 231 21 23 12 14 FIGS.A toB As shown, the hair planting apparatusincludes a base stageas a base support mechanism on which the base material J is placed, a feed devicethat feeds the placed base material J in one direction (referred to as X-axis direction) on the placement surface and another direction (referred to as Y-axis direction) orthogonal to the one direction, a clamp devicethat holds the base material J placed on the base stagefrom above, a hair holding mechanismthat holds the hair for planting M on one side (e.g., upper surface side) of the base material J supported on the base stage, a hair supply devicethat supplies the hair for planting M to the hair holding mechanism, a first capture mechanismthat pulls the hair for planting M held in the hair holding mechanismthrough a mesh hole Hto a back side (lower side) of the base material J to form a loop, a looper mechanismthat expands the loop (see), a second capture mechanismthat pulls the loop of the hair for planting M on the back side of the base material J from a neighboring mesh hole Hto a surface side (upper side) of the base material J, a third capture mechanismthat pulls one end portion of the hair for planting M into the small loop of the hair for planting M on the surface side and knots it between the mesh holes Hand H, and a moving mechanismthat performs a relative movement operation between the base material J and hook needlestoof the first to third capture mechanismsto.

10 11 28 11 21 61 511 51 511 62 30 63 30 64 65 30 100 12 10 Further, the hair planting apparatusincludes a cameraas an imaging unit that captures an image of the placed base material J, a position switch mechanismthat holds the cameraand the first capture mechanismand switches their positions, a wiper mechanismthat sweeps out the planted hair for planting M inserted in an upper openingof a clamp platedescribed below to the outside of the upper opening, an auxiliary clamp mechanismthat holds the base material J placed on the base stagein an auxiliary manner, a correction mechanismthat corrects an orientation of the base material J on the base stage, a first blower mechanismthat blows air to orient the hair for planting M planted in the base material J in a predetermined direction, a second blower mechanismthat blows air to press the base material J toward the base stage, a control devicethat controls operations of each configuration described above, a basethat directly or indirectly supports each configuration described above, and a cover (not shown) that houses the entire hair planting apparatus.

1 FIG. 1 FIG. Note that, in the following description, the placement surface on which the base material J is placed is horizontal, and one side in the Y-axis direction parallel to the placement surface is referred to as the “left” side, the other side is referred to as the “right” side, while one side in the X-axis direction parallel to the placement surface is referred to as the “front” side (side close to the paper surface in), and the other side is referred to as the “rear” side (side far from the paper surface in). Further, the vertical up-and-down direction orthogonal to the X-axis direction and the Y-axis direction is referred to as a Z-axis direction, and one side in the Z-axis direction is referred to as the “upper” side and the other side is referred to as the “lower” side.

1 FIG. 12 10 12 10 As shown in, the baseis a flat plate body that directly or indirectly supports the entire configuration of the hair planting apparatus. An upper surface of the baseis horizontal in a state in which the hair planting apparatusis installed on the horizontal surface.

21 22 28 23 11 24 61 62 63 64 12 The first capture mechanism, the second capture mechanism, the position switch mechanismthat supports the third capture mechanismand the camera, the looper mechanism, the wiper mechanism, the auxiliary clamp mechanism, the correction mechanism, and the first blower mechanismdescribed above are directly supported on the base.

Note that the term “directly supported” means that a configuration is installed without interposition of a mechanism for performing movement and its position in a plan view remains unchanged.

1 2 FIGS.and 25 26 12 27 26 As shown in, the moving mechanismincludes an X-axis stageinstalled on the upper surface of the base, and a Y-axis stageinstalled on the X-axis stage.

26 261 262 261 12 261 263 The X-axis stageincludes a stage platehaving an upper surface parallel to the X-Y plane, a slide guidethat supports the stage plateto be slidable along the X-axis direction with respect to the base, and a linear moving mechanism (not shown) that allows the stage plateto be moved and positioned arbitrarily in the X-axis direction. The linear moving mechanism includes a ball screw mechanism, and an X-axis motorincluding a servomotor serving as a drive source of the ball screw mechanism.

27 271 272 271 261 26 271 273 The Y-axis stageincludes a stage platehaving an upper surface parallel to the X-Y plane, a slide guidethat supports the stage plateto be slidable along the Y-axis direction with respect to the stage plateof the X-axis stage, and a linear moving mechanism (not shown) that allows the stage plateto be moved and positioned arbitrarily in the Y-axis direction. The linear moving mechanism includes a ball screw mechanism, and a Y-axis motorincluding a servomotor serving as a drive source of the ball screw mechanism.

30 40 50 65 271 27 The base stage, the feed device, the clamp device, and the second blower mechanismare directly supported on the stage plateof the Y-axis stage.

25 30 26 27 The moving mechanismcan position the base material J on the base stageat any position in the X-Y plane by cooperation of the X-axis stageand the Y-axis stage.

26 27 261 271 261 271 261 271 Note that, the linear moving mechanism of each of the X-axis stageand Y-axis stageis not limited to the ball screw mechanism and may be any mechanism that can position the stage plateorat any position along the X-axis direction or the Y-axis direction. For example, the linear moving operation of the stage plateormay be implemented by a configuration of a pinion-rack mechanism and a servomotor, or the stage plateormay be linearly moved by a linear motor.

6 FIG. 7 FIG. 30 is a plan view of the base stage, andis a perspective view.

30 32 31 27 25 33 32 34 33 As shown, the base stageincludes a base platesupported by four support posts(one is not shown in the drawing) erected on the Y-axis stageof the moving mechanism, a tower-like erected portionprovided on an upper surface of the base plate, and a placement plateserving as a placement part provided at an upper end portion of the erected portion.

33 32 The erected portionis erected at a central portion of the base platein a plan view.

34 33 341 34 The placement plateprovided at the upper end portion of the erected portionis a substantially rectangular frame-like body, and includes a work openinghaving a substantially rectangular shape and formed in a central portion thereof. In addition, an upper surface of the placement plateis a placement surface parallel to the X-Y plane.

34 34 34 21 341 34 22 23 341 34 During a hair planting operation, the base material J is placed and supported on the placement surface that is the upper surface of the placement plate. The placement plateis smaller than the base material J, and the base material J is placed with a lower surface portion thereof in partial contact with the placement plate. When performing a binding operation of the hair for planting M to the base material J, it is necessary to insert the hook needle of the first capture mechanisminto the mesh hole from the lower side of the base material J, but the insertion of the hook needle is performed through the work openingof the placement plate. In addition, the binding operation of the hair for planting M by the second and third capture mechanismsandis also performed within the range of the work openingof the placement plate.

6 7 FIGS.and 40 32 30 41 41 34 42 42 34 As shown in, the feed deviceincludes, on the base plateof the base stage, a pair of X-axis roller mechanismsandarranged on both sides of the placement platein the X-axis direction in a plan view, and a pair of Y-axis roller mechanismsandarranged on both sides of the placement platein the Y-axis direction in a plan view.

41 411 34 412 411 413 411 412 414 413 32 415 413 416 413 415 Each X-axis roller mechanismincludes a rollerthat comes into contact with the base material J from below, placed on the placement surface of the placement plate, an X-axis feed motorserving as a rotational drive source of the roller, a support bracketthat supports the rollerand the X-axis feed motor, two slide guidesthat support the support bracketon the base plateto be movable up and down along the Z-axis direction, two coil springsserving as elastic members to press the support bracketupward, and a retraction air cylinderthat pulls the support bracketdownward against the coil springs.

412 413 411 412 411 411 34 The X-axis feed motorsupported by the support bracketimparts feed rotation from an output shaft thereof to a rotation shaft of the rollerby a transmission mechanism including a pulley and a timing belt. The output shaft of the X-axis feed motorand the rotation shaft of the rollerare both arranged along the Y-axis direction. Therefore, when the rolleris driven to rotate in contact with the base material J from below, placed on the placement surface of the placement plate, the base material J can be fed in the X-axis direction.

42 421 34 422 421 423 421 422 424 423 32 425 423 426 423 425 Each Y-axis roller mechanismincludes a rollerthat comes into contact with the base material J from below, placed on the placement surface of the placement plate, a Y-axis feed motorserving as a rotational drive source of the roller, a support bracketthat supports the rollerand the Y-axis feed motor, a slide guidethat supports the support bracketon the base plateto be movable up and down along the Z-axis direction, a coil springserving as an elastic member to press the support bracketupward, and a retraction air cylinderthat pulls the support bracketdownward against the coil spring.

422 423 421 422 421 421 34 The Y-axis feed motorsupported by the support bracketimparts feed rotation from an output shaft thereof to a rotation shaft of the rollerby a transmission mechanism including a pulley and a timing belt. The output shaft of the Y-axis feed motorand the rotation shaft of the rollerare both arranged along the X-axis direction. Therefore, when the rolleris driven to rotate in contact with the base material J from below, placed on the placement surface of the placement plate, the base material J can be fed in the Y-axis direction.

416 426 413 423 415 425 413 423 411 421 34 34 411 421 In a state in which the retraction air cylindersandare not pulling the support bracketsanddownward and the coil springsandare pressing the support bracketsandto the top position, a height of an upper end portion of each of the rollersandis set to match a height of the placement surface (upper surface) of the placement plateor to be slightly lower than the placement surface of the placement plate. Each of the rollersandat the height is at a “feed position”.

416 426 413 423 411 421 34 411 421 In contrast, in a state in which the retraction air cylindersandare pulling the support bracketsanddownward, the height of the upper end portion of each of the rollersandis lowered to a height at which the lower surface of the base material J placed on the placement plateis not reached and a feed operation cannot be performed. Each of the rollersandat the height is at a “retraction position”.

41 42 411 41 34 When the pair of X-axis roller mechanismsis set at the feed position, the pair of Y-axis roller mechanismsis set at the retraction position, and the rollersof the pair of X-axis roller mechanismsare driven to rotate in the same direction, a conveying force in the X-axis direction can be applied to the base material J from both sides of the placement plate.

42 41 421 42 34 In addition, when the pair of Y-axis roller mechanismsis set at the feed position, the pair of X-axis roller mechanismsis set at the retraction position, and the rollersof the pair of Y-axis roller mechanismsare driven to rotate in the same direction, a conveying force in the Y-axis direction can be applied to the base material J from both sides of the placement plate.

41 42 In this way, the X-axis roller mechanismsand the Y-axis roller mechanismsdo not operate simultaneously, but separately perform conveying in the X-axis direction and conveying in the Y-axis direction.

411 41 34 In addition, when the rollersof the pair of X-axis roller mechanismsat the feed position are driven to rotate reversely in a direction of separating the base material J apart, the tension in the X-axis direction is applied to the base material J on the placement platesuch that slack can be suppressed.

421 42 34 In addition, when the rollersof the pair of Y-axis roller mechanismsat the feed position are driven to rotate reversely in a direction of separating the base material J apart, the tension in the Y-axis direction is applied to the base material J on the placement platesuch that slack can be suppressed.

41 42 Hereinafter, the operation control of applying tension to the base material J in each direction by the pair of X-axis roller mechanismsor the pair of Y-axis roller mechanismsis referred to as “tension applying control”.

25 34 341 21 23 During the hair planting operation of binding the hair for planting M to the base material J, the moving mechanismdescribed above is used for moving the base material J together with the placement plate, and positioning each mesh hole of the base material J in the range of the work openingwith respect to the hook needles of the first to third capture mechanismsto.

40 34 341 34 In contrast, the feed deviceis used for moving the base material J with respect to the placement plateand shifting the range of the base material J facing the work openingof the placement plateto another position in the base material J.

25 40 Therefore, the movement of the base material J by the moving mechanismis finely controlled by a very small amount of movement compared with the movement of the base material J by the feed device.

41 42 Note that, while the configuration in which the roller mechanismsandin two intersecting directions respectively perform the feed in the X-axis direction and the Y-axis direction orthogonal to each other is shown herein, aspects are not limited thereto, and a configuration in which the feed is performed in two obliquely intersecting directions is also possible.

30 35 30 40 35 411 421 34 30 Note that the base stageincludes a cover memberthat covers the base stageand the feed device. The cover memberhas a substantially convex polyhedron shape with an upper end portion thereof protruding upward, and a center of the upper end portion is widely cut out such that the upper portions of the rollersandand the placement plateare respectively exposed upward. The upper end portion of the base stagemay have a polyhedral shape closer to a spherical shell or may have a substantially spherical shell shape.

35 34 411 421 40 32 40 With the cover member, the base material J placed on the placement plateis prevented from direct contact with the configurations other than the respective rollersandof the feed device, with the corners of the base plate, or the like, allowing a smooth feed operation of the base material J by the feed device.

35 1 FIG. Note that the cover memberis omitted in the drawings other than.

1 3 5 FIGS.andto 50 51 30 52 271 27 51 53 51 52 54 51 55 52 51 51 As shown in, the clamp deviceincludes a clamp plate (clamp member)including a flat plate body elongated in the Y-axis direction above the base stage, a pair of support baseserected on the upper surface of the stage plateof the Y-axis stageto individually support both end portions of the clamp plate, a slide guidethat allows lifting and lowering of the clamp platewith respect to each support base, a clamp air cylinderserving as a lifting/lowering unit that lifts and lowers the clamp plate, and a coil springprovided between each support baseand the clamp plateand serving as an elastic member to press the clamp plateupward.

50 271 27 50 30 25 Since the clamp deviceis supported on the stage plateof the Y-axis stage, the clamp deviceis moved in the X-Y directions together with the base stageby the moving mechanism.

341 34 51 511 341 At a position directly above the work openingof the placement plate, the clamp plateis formed with an upper openingpenetrating vertically therethrough and having substantially the same shape and size as those of the work opening.

51 34 51 34 A lower surface of the clamp platecan be brought into contact with the placement surface of the placement plateat a lower limit position of the lifting and lowering operation. The clamp platecan clamp the base material J placed on the placement platefrom above to fixedly hold the base material J by being lowered to the lower limit position.

341 34 511 Furthermore, at the lower limit position of the lifting and lowering operation, the work openingof the mounting plateand the upper openingcan be overlapped at substantially the same position in a plan view.

22 23 51 341 511 The second and third capture mechanismsanddescribed above are arranged above the clamp plate, and extend the hook needles downward to perform a binding operation of the hair for planting M within a range of the base material J in the work openingthrough the upper opening.

512 411 421 511 51 512 51 411 421 51 51 34 411 421 41 42 In addition, four contact platesthat individually come into contact with outer circumferences of the respective rollersandare provided on four sides of the upper openingon the lower surface side of the clamp plate. Each contact platehas a lower surface positioned lower than the lower surface of the clamp plate, and comes into contact with an upper portion of each of the rollersandat a position immediately before the clamp platelowers to the lower limit position of the lifting and lowering operation. In this way, by lowering the clamp plateto a position immediately before the lower limit position, the base material J on the placement platecan be properly brought into contact with each of the rollersand, and the feed operation by the pair of X-axis roller mechanismsor the pair of Y-axis roller mechanismscan be performed properly.

8 10 FIGS.to 50 51 are front views of the clamp devicewith the clamp plateat different heights, respectively.

8 FIG. 51 54 51 34 shows a state in which the clamp plateis positioned at a lifted position, which is an upper limit of the lifting and lowering operation, by lifting pressure of each clamp air cylinder. In this state, the lower surface of the clamp plateis significantly spaced apart from the placement surface of the placement plate.

34 51 34 611 61 At the lifted position, the base material J on the placement plateis in an unclamped state. Since the clamp plateat the lifted position is significantly spaced apart from the placement plate, the hair for planting M can be swept out through a wiper memberof the wiper mechanismdescribed below.

54 56 51 54 100 Each clamp air cylinderis provided with a regulatorin a supply path from a pneumatic source, and air pressure for lowering the clamp platecan be applied to each clamp air cylinderin two stages of high and low pressures, under control of the control device.

9 FIG. 10 FIG. 51 54 51 54 shows a state of the clamp platewhen the lowering pressure of each clamp air cylinderis at a low pressure, andshows a state of the clamp platewhen the lowering pressure of each clamp air cylinderis at a high pressure.

9 FIG. 54 51 55 51 34 51 As shown in, when the lowering pressure of each clamp air cylinderis at a low pressure, the lowered clamp platecannot withstand the upward pressing force received from the coil spring, so that a gap d is formed between the lower surface of the clamp plateand the placement surface of the placement plate, and the base material J is brought into a state of being restrained by a small clamping force of the clamp or not restrained. The height of the clamp plateat this time is referred to as a weak clamp position.

512 51 411 421 411 421 34 512 411 421 41 42 On the other hand, at this weak clamp position, each contact plateof the clamp platecontacts each of the rollersandor forms a very narrow gap with respect to each of the rollersand. Therefore, when the base material J is placed on the placement plate, the base material J is pushed by each contact plateinto contact with each of the rollersandwith an appropriate contact force such that the feed operation by the pair of X-axis roller mechanismsor the pair of Y-axis roller mechanismscan be performed properly.

10 FIG. 54 51 51 34 55 34 51 34 51 In contrast, as shown in, when the lowering pressure of each clamp air cylinderis at a high pressure, the lowered clamp platecan allow the lower surface of the clamp plateand the placement surface of the placement plateto be brought into pressure contact with each other, against the coil spring. Therefore, when the base material J is placed on the placement plate, the base material J is firmly gripped by the clamp plateand the placement plateand fixedly held with a large restraining force. The height of the clamp plateat this time is referred to as a strong clamp position.

57 51 57 511 11 341 34 57 51 511 Additionally, a lighting deviceis provided on the upper surface of the clamp plate. The lighting deviceirradiates illumination light from above the upper openingwhen the cameradescribed below captures an image of the base material J through the work openingfrom below the placement plate. The lighting deviceis retracted to one end portion side of the clamp plateduring non-imaging, and is moved directly above the upper openingby an actuator (not shown) to project light downward during imaging.

11 FIG. 74 68 is a right side view of the hair supply deviceand the hair holding mechanism.

74 12 30 The hair supply deviceis installed on the baseat a position on a front left side of the base stage.

74 The hair supply deviceallows a spatula member to be inserted near an upper end portion of a bundle Mb of numerous hairs for planting M held upright along the vertical direction so as to separate several hairs for planting M, and further to be rotated so that the upper end portions of the separated hairs for planting M are tilted to face rearward.

74 741 741 741 74 11 FIG. In addition, the hair supply deviceincludes a headthat suctions and internally grips a tip portion of one of the plurality of tilted hairs M for planting, and conveys the headrearward in the X-axis direction so that one hair for planting M can be pulled out straight rearward. In, reference sign Mp denotes a pull-out position of the hair for planting M targeted by the headof the hair supply device.

74 741 Note that the hair supply deviceincludes a gripping mechanism (not shown) that grips a front end portion side of the hair for planting M pulled out by the headto the pull-out position Mp.

11 FIG. 68 12 74 30 As shown in, The hair holding mechanismis installed on the baseat a position located rearward of the hair supply deviceand to the left of the base stage.

68 69 70 71 75 69 The hair holding mechanismincludes a first gripping mechanismand a second gripping mechanismthat grip both end portions of the hair for planting M, respectively, a conveying mechanismthat supports and conveys the gripping mechanisms along the Y-axis, and a recovery devicethat recovers the hair for planting M that remains in the first gripping mechanismdue to an error or the like.

71 711 712 711 716 The conveying mechanismincludes a movable bodyhaving a flat plate shape along the X-Y plane, a support bodyhaving an elongated flat plate shape and erected at a right end portion of the movable body, and a feed motorserving as an actuator.

712 69 70 The support bodysupports the first gripping mechanismand the second gripping mechanismarranged in the front-rear direction in the right plane.

711 716 69 70 The movable bodyis conveyed along the Y-axis direction by driving of the feed motor, thereby allowing the first gripping mechanismand the second gripping mechanismto be arbitrarily moved and positioned along the Y-axis direction.

69 72 The first gripping mechanismincludes a structure similar to a thread tensioner device mounted on a sewing machine, two sliding plates that grip the hair for planting M with spring pressure, and a release mechanismthat switches a gripped state to a released state.

The two sliding plates are disk-shaped plates pivotally supported in a vertically overlapping state, and their outer circumferences are slightly bent backward to separate the sliding plates from each other, thereby forming a gap.

71 Therefore, when the two sliding plates are moved rightward by the conveying mechanismwith respect to the hair for planting M at the pull-out position Mp described above, the hair for planting M can enter through the gap between the two sliding plates and can be gripped.

72 69 724 The release mechanismincludes an insertion plate that can be inserted between the two sliding plates of the first grip mechanismfrom the left, and a release air cylinderthat imparts a reciprocating motion to the insertion plate along the Y-axis.

724 The insertion plate is inserted between two sliding plates when advanced rightward by the release air cylinder, thereby opening the two sliding plates and switching the hair for planting M from a gripped state to a released state. The insertion plate has a length that reaches right ends of the two sliding plates, and can discharge rightward the hair for planting M gripped by the two sliding plates.

70 704 705 The second gripping mechanismincludes two gripping members that grip the hair for planting M, and gripping air cylindersandas lifting and lowering actuators for individually lifting and lowering the respective gripping members.

The two gripping members have flat extensions extending rightward, and are supported such that a lower surface of one extension and an upper surface of the other extension are aligned vertically.

704 705 One gripping member is supported so as to be switchable in position between upper and lower positions by the gripping air cylinder, and the other gripping member is supported so as to be switchable in position between upper and lower positions by the gripping air cylinder.

704 705 Therefore, the hair for planting M can be gripped by bringing the extensions of the two gripping members into pressure contact with each other with the gripping air cylindersand, and the hair for planting M can be released by separating the extensions of the two gripping members.

69 70 74 30 The first gripping mechanismand the second gripping mechanismgrip the hair for planting M supplied by the hair supply deviceat a receiving position slightly to the right of a retraction position most leftward away from the base stage.

69 70 511 51 In addition, the first gripping mechanismand the second gripping mechanismmove rightward from the receiving position and hold the hair for planting M at a supply position located above the upper openingof the clamp plate. At the supply position, a knotting work (binding work) of the hair for planting M to the base material J is performed.

69 70 69 70 Furthermore, the first gripping mechanismand the second gripping mechanismperform, at a recovery position between the receiving position and the supply position in the Y-axis direction, a release operation of the hair for planting M by the first gripping mechanism(with respect to the second gripping mechanism, the hair for planting M is released during the binding process of the hair for planting M).

69 At the recovery position, the hair for planting M that remains gripped by the first gripping mechanismdue to an error or the like in the work is recovered.

75 At the recovery position, the recovery devicefor the hair for planting M is arranged.

75 751 752 751 751 752 2 FIG. The recovery deviceincludes a suction nozzleexpanded rearward, an intake blower(see) in communication with the suction nozzle, and a trap (not shown) formed of a mesh or the like for repair of the hair for planting M and provided between the suction nozzleand the intake blower.

75 752 72 69 The recovery devicedrives the intake blowerwhen the release mechanismis in operation, thereby suctioning and recovering the hair for planting M, if any, discharged from the first gripping mechanism.

21 23 24 20 The first to third capture mechanismstoand the looper mechanismconstitute the hair planting unitthat knots and binds the hair for planting M to the base material J.

21 23 211 231 211 231 The first to third capture mechanismstorespectively include hook needlestoeach having a barb provided near a tip, ball screw mechanisms (not shown) for moving the hook needles forward and backward, and capture motors (not shown) serving as drive sources for lifting and lowering operations of the hook needlesto.

21 341 34 211 34 25 21 12 341 211 34 25 The first capture mechanismis arranged below the work openingof the placement plate, with the hook needleoriented vertically upward. The placement platecan move in the X-Y direction by the moving mechanism. The first capture mechanismis arranged on the baseso that a center position of the work openingand the hook needleare aligned in a plan view, with the placement platepositioned at a preset reference position by the moving mechanism.

22 511 51 221 The second capture mechanismis arranged above the upper openingof the clamp plate, with the hook needleoriented vertically downward.

221 22 12 211 21 22 12 The hook needleof the second capture mechanismis arranged above the baseso as to be slightly to the left of the hook needleof the first capture mechanismin a plan view. Note that, strictly, the second capture mechanismis supported on a support plate (not shown) erected on the base.

22 221 21 23 211 231 The second capture mechanismalso includes an actuator that turns the hook needle. The first and third capture mechanismsandmay also include actuators that turn the hook needlesand, respectively.

23 511 51 22 231 The third capture mechanismis arranged above the upper openingof the clamp plateand behind the second capture mechanism, with the hook needleoriented obliquely forward and downward.

231 23 12 221 22 34 23 12 The hook needleof the third capture mechanismis arranged above the baseso that its center line intersects a center line of the hook needleof the second capture mechanismat a position slightly above the placement surface of the placement plate. Note that, strictly, the third capture mechanismis also supported on the support plate (not shown) erected on the base.

24 21 34 The looper mechanismis arranged above the first capture mechanismand below the lower surface of the placement plate.

24 241 21 24 241 241 The looper mechanismincludes a pair of arm portionsextended to the right to widen a loop of the hair for planting M pulled into the lower side of the base material J by the first capture mechanism. Additionally, the looper mechanismincludes an actuator that separates tip portions of the pair of arm portionsin the X-axis direction, and an actuator that moves the pair of arm portionsalong the Y-axis direction.

20 20 The configuration of the hair planting unitand the binding operation of the hair for planting M to the base material J are substantially the same as those disclosed in JP2018-040084A. Therefore, reference is made to the above publication for the details of the configuration of the hair planting unitand the binding operation of the hair for planting M to the base material J, and only a brief description will be provided herein.

12 14 FIGS.A toB 12 13 14 FIGS.A,A, andA 12 13 14 FIGS.B,B, andB 24 are explanatory diagrams of the binding operation of the hair for planting M.show the periphery of the looper mechanismin a right side view, andshow the periphery in a rear view.

69 70 24 In addition, in each drawing, the first gripping mechanismand the second gripping mechanismdescribed above are schematically shown, but for the sake of explanation, they are shown smaller in size than in reality and closer to the looper mechanismthan in reality.

12 12 FIGS.A andB 69 70 34 In the binding operation of the hair for planting M, as shown in, the hair for planting M is supported along the front-rear direction by the first gripping mechanismand the second gripping mechanismon the upper side of the base material J held on the upper surface of the placement plate.

211 21 1 1 In this state, the hook needleof the first capture mechanismadvances and retracts from below through the mesh hole Hof the base material J, captures the hair for planting M, and pulls it into the mesh hole Hto form a loop.

241 24 241 2 Furthermore, the pair of arm portionsof the looper mechanismis allowed to enter the loop of the hair for planting M by rightward movement, and moves leftward while opening the pair of arm portionsto pull the loop to the lower side of the adjacent mesh hole Hon the left.

221 22 2 2 Then, the hook needleof the second capture mechanismadvances and retracts from above through the mesh hole Hof the base material J, captures the loop of the hair for planting M, and pulls it into the mesh hole Hto form a small loop on the upper side of the base material J.

13 13 FIGS.A andB 221 22 231 23 69 Then, as shown in, the hook needleof the second capture mechanismturns to impart a twist to the small loop, and the hook needleof the third capture mechanismadvances from an obliquely rearward and upward direction, enters the small loop, and captures an end portion of the hair for planting M on the first gripping mechanismside.

14 14 FIGS.A andB 231 23 69 221 22 24 241 Then, as shown in, the hook needleof the third capture mechanismretracts to insert the entire end portion on the first gripping mechanismside into the small loop of the hair for planting M, the hook needleof the second capture mechanismcomes out of the small loop, and the looper mechanismmoves the pair of arm portionsleftward to release the hair for planting M.

69 231 1 2 70 A terminal end of the hair for planting M is pulled out from the first gripping mechanismwhile sliding, and passes through the small loop. Furthermore, the hair for planting Mis tensioned by the hook needleuntil it is knotted to a boundary portion between the mesh hole Hand the mesh hole H, and the second gripping mechanismreleases the hair for planting M, whereby the binding operation of the hair for planting M is completed.

231 23 Note that the hook needleof the third capture mechanismmay be provided with a gripping mechanism for holding the captured state of the hair for planting M.

3 FIG. 62 30 62 41 As shown in, the auxiliary clamp mechanismsare provided on both sides of the base stagein the X-axis direction, respectively. The two auxiliary clamp mechanismsare arranged to individually face the two X-axis roller mechanisms.

62 621 622 621 Each of the auxiliary clamp mechanismsincludes an auxiliary clamp plateprovided to be tiltable, and an auxiliary clamp air cylinderfor tilting the auxiliary clamp plate.

621 411 41 The auxiliary clamp plateis formed as a flat plate having a base end portion tiltably supported about the Y-axis and a tip portion in contact with the outer circumferential surface of the rollerof the X-axis roller mechanism.

622 621 411 34 41 621 The auxiliary clamp air cylinderapplies tilting force in a direction in which the tip portion of the auxiliary clamp platecomes into contact with the outer circumferential surface of the roller. As a result, the base material J placed on the placement plateis sandwiched and held between the X-axis roller mechanismand the tip portion of the auxiliary clamp plate.

62 34 51 50 34 For example, the two auxiliary clamp mechanismsare provided to press the base material J so as to prevent misalignment of the base material J with respect to the placement plate, when the clamp plateof the clamp deviceis set to the lifted position and the base material J on the placement plateis released.

62 621 41 When the base material J is clamped by the two auxiliary clamp mechanisms, the base material J is likely to become slack due to the pressing by the tip portion of the auxiliary clamp plate. Therefore, it is preferable to simultaneously perform the tension applying control by the pair of X-axis roller mechanismsdescribed above.

3 4 FIGS.and 61 As shown in, the wiper mechanismis a mechanism for sweeping the hair for planting M bound to the base material J.

341 511 51 As described above, the operation of planting hair to the base material J is performed through the work openingand the upper openingwhile the base material J is held by the clamp plate.

51 511 In this case, each hair for planting M bound to the base material J protrudes upward of the clamp platethrough the upper opening.

341 34 51 40 341 On the other hand, when the planting of the hair for planting M is completed in one section in the work openingof the placement platein the base material J, the clamp plateis lifted to the weak clamp position, and the feed deviceperforms the feed operation of the base material J such that an adjacent section is within the work opening.

511 341 Then, if each hair for planting M that has been planted remains inserted in the upper opening, it may possibly affect the feed operation of the base material J, the binding operation of the hair for planting M in the next section, the image capturing of a new section through the work opening, and the like.

51 61 51 511 Therefore, the clamp plateis lifted to the lifted position, and the operation of sweeping, with the wiper mechanism, the hair for planting M bound to the base material J below the clamp plateand sweeping out each hair for planting M from the upper openingis performed.

Note that the operation of feeding the base material J and the operation of sweeping out the hair for planting M may be performed in reverse order.

3 FIG. 61 34 61 51 34 As shown in, the wiper mechanismis arranged on a rear right side of the mounting platein a plan view. In addition, the wiper mechanismis arranged lower than the clamp plateat the lifted position and higher than the placement plate.

61 611 612 611 613 611 The wiper mechanismincludes a rod-shaped wiper memberthat sweeps each hair for planting M, a telescopic air cylinderthat extends and contracts the wiper member, and a sweeping-out air cylinderthat moves the wiper memberforward and rearward for sweeping-out.

611 612 The wiper memberhas a round rod shape along the Y-axis direction and extends leftward from the telescopic air cylinder.

612 613 612 611 611 611 The telescopic air cylinderis supported by the sweeping-out air cylinderso that a plunger moving forward and rearward is parallel to the Y-axis direction. The plunger of the telescopic air cylinderis directly connected to the wiper memberin the extending direction thereof and can switch between a state in which the wiper memberis contracted rightward and a state in which the wiper memberis extended leftward.

611 34 611 34 In the contracted state, the wiper memberis positioned to the right of the placement plate, and in the extended state, the wiper memberoverlaps the placement platein the Y-axis direction.

613 12 612 611 34 34 The sweeping-out air cylinderis supported by the baseso that the plunger is parallel to the X-axis direction. The telescopic air cylindercan be supported at the tip portion of the plunger, and the wiper membercan be moved forward of the placement platewhen the plunger is advanced, and rearward of the placement platewhen the plunger is retracted.

341 34 51 61 611 613 611 612 611 613 With the above configuration, when binding the hair for planting M to one section in the work openingof the placement plateis completed and the clamp plateis lifted to the lifted position, the wiper mechanismadvances the wiper memberby the sweeping-out air cylinder, extends the wiper memberby the telescopic air cylinder, and then retracts the wiper memberby the sweeping-out air cylinder.

611 341 34 511 51 511 As a result, the wiper membercan pass between the work openingof the placement plateand the upper openingof the clamp plate, sweep each hair for planting M rearward, and sweep it out through the upper opening.

611 611 Note that the wiper membermay take any form as long as it can sweep the hair for planting M. For example, the wiper memberis not limited to a round rod shape and may take the shape of a plate or a brush.

64 64 34 51 34 3 4 FIGS.and The first blower mechanismhas a nozzle connected to a pneumatic supply source. As shown in, the first blower mechanismis arranged forward of and slightly above the placement plate, and below the clamp plateat the lifted position, and blows air obliquely rearward and downward toward the placement plateside.

61 50 34 51 As described above, the hair for planting M collectively swept rearward by the wiper mechanismtends to rise upward of the base material J from the state of being swept rearward due to the elasticity thereof. In this case, when clamping the base material J to a new section by the clamp device, there is a risk that the hair for planting M will be caught between the placement plateand the clamp plate.

64 61 For this reason, the first blower mechanismblows air to the hair for planting M swept rearward by the wiper mechanismso that the hair does not rise.

65 65 51 65 34 51 1 FIG. The second blower mechanismhas a nozzle connected to a pneumatic supply source. As shown in, the second blower mechanismis provided at each of both end portions of the clamp platein the Y-axis direction, and each of the second blower mechanismsblows air toward the placement plateside, on the lower side of the clamp plate.

65 35 411 421 51 34 These second blower mechanismshave a function of blowing air to press the base material J against the cover memberand the respective rollersandwhen the clamp plateis lifted to release the base material J on the placement plate.

65 40 341 61 In addition, the second blower mechanismshave a function of blowing air toward the downstream side in the feed direction of the base material J to push the hair for planting M toward the downstream side in the feed direction of the base material J when the feed devicefeeds the base material J such that the adjacent section in the Y-axis direction is within the work opening, and the wiper mechanismperforms the sweeping operation.

1 FIG. 11 34 341 11 As shown in, the cameracaptures an image of the base material J from below the placement platethrough the work opening. The cameraincludes an image sensor such as a charge-coupled device (CCD) or a complementary metal oxide semiconductor (CMOS) and an optical system.

11 28 21 11 21 283 28 11 341 21 2 FIG. The camerais supported by the position switch mechanism(see) together with the first capture mechanism. The cameraand the first capture mechanismcan be switched in position by a position switch air cylinderof the position switch mechanismbetween a state in which an optical axis of the camerais aligned with the center line along the Z-axis direction passing through the center of the work openingand a state in which the center line of the hook needle held by the first capture mechanismis aligned with the center line.

28 12 12 34 12 25 34 28 341 341 34 25 34 Note that the position switch mechanismis installed directly on the baseand does not cause movement on the base. In contrast, the placement plateis installed on the basevia the moving mechanism. Therefore, in a plan view, the placement plateis relatively movable in the X-axis direction and the Y-axis direction with respect to the position switch mechanism. For this reason, the “center of the work opening” refers to the center of the work openingin a state in which the placement plateis positioned at the center of the movable range by the moving mechanism(as the reference position of the placement plate).

34 40 The base material J is a mesh material with mesh holes aligned and developed on its surface. For example, the base material J of the present embodiment has hexagonal mesh holes aligned. When performing the operation of sequentially binding the hair for planting M to each mesh hole of the base material J, the alignment direction of the mesh holes is held on the placement plateso as to be parallel to the X-axis or Y-axis direction, which is the feed direction of the feed device.

However, the alignment direction of the mesh holes may be inclined due to a variety of factors, such as when displacement occurs due to sliding of the base material J during feeding, when the base material J is not planar but has a three-dimensional shape or is made of a soft material that is easily deformable, and the like.

11 The inclination of the mesh holes of the base material J can be detected from the image captured by the camera.

30 63 11 63 When the inclination of the mesh holes of the base material J exceeds an allowable value, the orientation of the base material J on the base stagecan be corrected by the correction mechanism, which rotates the base material J about the Z-axis with respect to the cameraby the correction mechanism.

63 34 63 632 631 12 633 632 634 633 635 634 636 632 3 5 FIGS.to 2 FIG. 2 FIG. The correction mechanismis arranged in front of the placement plate, as shown in. The correction mechanismincludes a support shaftrotatably supported around the Z-axis by a bracketinstalled on the base, an armfixed to an upper end portion of the support shaft, a disc-shaped pressing plateprovided at a tip portion of the arm, a correction motor(see) that rotates the pressing platevia a belt mechanism, and an arm turning air cylinder(see) that imparts rotational motion to the support shaft.

632 631 The support shaftis supported along the Z-axis direction by the bracket.

633 632 637 633 632 632 637 The armis connected to the support shaftvia a spline nut. That is, the armcan be moved along the support shaftand rotated around the Z-axis together with the support shaftby the spline nut.

633 638 637 In addition, the armis pressed upward by a coil spring, which is an elastic member, via the spline nut.

634 633 633 634 635 633 634 30 634 The pressing plateprovided on a lower surface side of the tip portion of the armis rotatably supported around the Z-axis at the tip portion of the arm. The pressing plateis imparted with rotational motion from the correction motorby a belt mechanism provided on the upper surface side of the arm. In addition, the lower surface side of the pressing platecontacts the base material J placed on the base stagefrom above, so that the rotation of the pressing platecan be imparted to the base material J.

633 638 634 30 In addition, the armis always pressed upward by the coil spring, thereby keeping the pressing plateat a height away from the base material J on the base stage.

639 633 638 633 634 34 A pressing air cylinderfor lowering the armagainst the coil springis arranged in parallel with the arm, and when performing correction by rotation of the base material J, the pressing platecan be lowered to contact the base material J on the placement plate.

636 632 632 In addition, the arm turning air cylinderinputs rotational motion to the support shaftvia a link member (not shown) provided at a lower end portion of the support shaft.

636 633 634 34 34 By the rotational motion input from the arm turning air cylinder, the armcan move the pressing platebetween a retraction position in front of the placement plateand a pressing position directly above the placement plate.

2 FIG. 100 10 102 103 104 101 102 As shown in, the control deviceof the hair planting apparatusincludes a read only memory (ROM)that stores a program for controlling a hair planting operation, a random access memory (RAM)serving as a work area for arithmetic processing, a non-volatile data memorywhich serves as a storage means for storing various setting data or the like and to which the setting data can be rewritten, and a central processing unit (CPU)that executes programs in the ROM.

101 21 23 24 25 20 In addition, the CPUis connected to the first to third capture mechanismsto, the looper mechanism, and the moving mechanismthat constitute the hair planting unit.

21 23 211 231 101 Each of the first to third capture mechanismstoincludes a capture motor serving as a drive source for advancing and retracting operations of each of the hook needlesto, and the CPUcontrols their operations through a drive circuit (not shown) that operates them.

24 101 24 The looper mechanismincludes a plurality of actuators, and the CPUcontrols the operation of the looper mechanismthrough a drive circuit (not shown) that operates the actuators.

25 26 27 101 26 27 263 26 273 27 The moving mechanismincludes the X-axis stageand the Y-axis stage, and the CPUcontrols the operations of the X-axis stageand the Y-axis stagethrough a drive circuit (not shown) that operates the X-axis motorof the X-axis stageand the Y-axis motorof the Y-axis stage.

101 28 11 21 283 In addition, the CPUis connected to the position switch mechanismthat switches the positions of the cameraand the first capture mechanism, and controls the position switch air cylinderthrough an electromagnetic valve (not shown).

101 41 412 416 In addition, the CPUis connected to the X-axis roller mechanism, controls the X-axis feed motorthrough a drive circuit (not shown), and controls the retraction air cylinderthrough an electromagnetic valve (not shown).

101 42 422 426 Similarly, the CPUis connected to the Y-axis roller mechanism, controls the Y-axis feed motorthrough a drive circuit (not shown), and controls the retraction air cylinderthrough an electromagnetic valve (not shown).

41 42 2 FIG. Note that, although two X-axis roller mechanismsand two Y-axis roller mechanismsare provided,shows only one of them, respectively.

101 50 54 54 56 In addition, the CPUis connected to the clamp device, controls the clamp air cylinderthrough an electromagnetic valve (not shown), and controls the strength of the air pressure supplied to the clamp air cylinderby the regulator.

101 57 57 In addition, the CPUis connected to the lighting device, switches ON/OFF of illumination light irradiation, and controls an actuator to move the lighting deviceto a predetermined position.

101 61 612 613 In addition, the CPUis connected to the wiper mechanismand controls the telescopic air cylinderand the sweeping-out air cylinderthrough electromagnetic valves (not shown) connected to each thereof.

101 62 622 In addition, the CPUis connected to the auxiliary clamp mechanismand controls the auxiliary clamp air cylinderthrough an electromagnetic valve (not shown).

62 2 FIG. Note that, although two auxiliary clamp mechanismsare provided, only one is shown in.

101 63 635 636 639 In addition, the CPUis connected to the correction mechanism, controls the correction motorthrough a drive circuit (not shown), and controls the arm turning air cylinderand the pressing air cylinderthrough electromagnetic valves (not shown) connected to each thereof.

64 65 101 In addition, both the first blower mechanismand the second blower mechanisminclude electromagnetic valves for supplying high-pressure air to the nozzles, and the CPUcontrols each electromagnetic valve to control discharge of the air.

101 68 716 704 705 724 752 In addition, the CPUis connected to the hair holding mechanism, controls the conveying motorthrough a drive circuit (not shown), controls the gripping air cylindersandand the release air cylinderthrough electromagnetic valves (not show) connected to each thereof, and controls the intake blowerthrough a drive circuit (not shown).

101 11 In addition, the CPUis connected to the cameraand controls the execution of image capturing of the base material J.

101 14 In addition, the CPUis connected to a pedalfor inputting the start of the hair planting operation.

101 15 In addition, CPUis connected to an operation panelhaving a function as a display unit for displaying various information and a function as an input unit for performing various inputs.

101 105 106 107 108 In addition, the CPUincludes software modules such as an image acquisition unit, a transformation matrix acquisition unit, a difference processing unit, and a hair detection unit. Note that part or all of the software modules may be implemented by hardware.

10 The functions of the software modules described above will be appropriately described in the operation control of the hair planting operation by the hair planting apparatusdescribed below.

101 Note that the CPUcontrols various air cylinders, various motors, various actuators, and the like through electromagnetic valves, drive circuits, interfaces, and the like. However, in the following description, descriptions of the electromagnetic valves, drive circuits, and interfaces will be omitted, and it will simply be described that various air cylinders, various motors, various actuators, and the like are controlled.

101 15 FIG. The overall flow of operation control of the hair planting operation executed by the CPUis shown in a flow chart of.

101 54 50 51 622 62 621 41 First, as a preliminary preparation, the CPUcontrols the clamp air cylinderof the clamp deviceto move the clamp plateto the lifted position, and controls the auxiliary clamp air cylindersof the respective auxiliary clamp mechanismsto move the auxiliary clamp platesto the released position spaced from the X-axis roller mechanism.

101 1 Then, the CPUexecutes a step of base set (step S).

34 30 14 101 54 56 51 That is, when the base material J is placed on the placement plateof the base stageand the start of the hair planting operation is input from the pedal, the CPUsupplies low-pressure air to the clamp air cylinderby the regulatorand lowers the clamp plateto the weak clamp position.

101 3 Next, the CPUexecutes a step of inclination detection (step S).

101 283 28 11 11 341 That is, the CPUcontrols the position switch air cylinderof the position switch mechanismto position the camerasuch that the optical axis of the cameracoincides with the center of the work openingat the reference position.

101 57 511 In addition, the CPUcontrols the lighting deviceto move above the upper openingand to irradiate illumination light downward.

11 341 101 In addition, the cameracaptures an image of the base material J within the range of the work opening, and the CPUextracts a plurality of mesh holes developed on the surface of the base material J from the captured image, and detects a centroid point g of each mesh hole.

16 FIG. 11 shows an example of an image captured by the camera.

16 FIG. 101 11 As shown in, the CPUspecifies a centroid point gc closest to the center of the camera (the optical axis of the camera), and further specifies two centroid points g adjacent in sequence above and two centroid points g adjacent in sequence below the centroid point gc such that the centroid points are linearly aligned and the total number of points is five, which is the reference number of points. The term “adjacent” herein refers to a state of being adjacent to each other at the closest interval. In addition, the “closest interval” refers to the interval between the centroid points of mesh holes that are adjacent with their sides in contact, for example, in the case of mesh holes of a regular polygon such as a regular hexagon.

Note that, when there is no particular need to distinguish a specific centroid point gc or a centroid point gn described below, from the other centroid points g, these will also be simply referred to as the “centroid point g”.

101 Then, the CPUobtains an inclination angle θ of the straight line I passing through the five vertically adjacent centroid points g with respect to the X-axis direction (vertical direction in the image). This is an inclination of the base material J.

If the inclination angle θ is within an allowable range, the base material J is determined to be not inclined, and if the inclination angle θ exceeds the allowable range, the base material J is determined to be inclined.

101 Additionally, a case may occur in which the mesh holes or the centroid points are not favorably detected, and only a number of centroid points g smaller than the reference number of points can be detected. In this case, the CPUconsiders a centroid point gn of a mesh hole adjacent in one Y-axis direction to the mesh hole of the centroid point gc as a new centroid point gc, detects five centroid points g including the centroid point gn adjacent in the X-axis direction, and performs determination of inclination.

In addition, when five centroid points g cannot be obtained for the centroid point gn, attempts to acquire five centroid points g for the centroid point gn are performed up to a specified maximum number of times (e.g., twice on each of the left and right sides) with respect to both sides in the Y-axis direction of the original centroid point gc, and when five centroid points g still cannot be obtained, the inclination detection is stopped. In this case, an error May be notified and the hair planting operation may be interrupted, or the step of inclination detection and the next step of correction control may be skipped and the subsequent hair planting operation may be continued. Note that, if continued, the hair planting operation is performed with slightly lower accuracy.

101 5 3 Next, the CPUexecutes a step of correction control (step S). The correction control is performed when it is determined in step Sthat the base material J is inclined. In addition, when it is determined that there is no inclination, this step is skipped.

101 63 635 634 40 As the correction control, the CPUcontrols the correction mechanism, and rotates the base material J in a direction in which the detected inclination angle is corrected, by the correction motorthat holds the base material J from above with the pressing plate. Before and after the inclination correction, the slack of the base material J may be eliminated by the tension applying control by the feed device.

101 51 50 411 421 40 Then, the CPUlowers the clamp plateof the clamp deviceto the weak clamp position and lifts each of the rollersandof the feed deviceto the feed position.

101 105 11 341 34 7 Next, the CPUfunctions as an image acquisition unitand, before the hair planting operation, performs a pre-imaging step in which the cameracaptures an image of the base material J within the range of the work openingof the placement plate(step S).

104 341 17 FIG. Here, the hair planting pattern data stored in advance in the data memorywill be described based on. The hair planting pattern data is data in which settings are defined for the hair planting operations for a plurality of mesh holes included in one unit section within the range of the work opening.

As shown, in the hair planting pattern data, a plurality of hair planting positions are set along with the order of hair planting at respective positions on a plane where all of the mesh holes are regular hexagons arranged at uniform intervals. Reference sign K in the drawing indicates the unit section described above. Within the unit section K, seventy-two mesh holes are present, and the hair planting position is indicated by a mark ‘o’ for each mesh hole. For each hair planting position, the order of hair planting is also defined.

25 11 In the pre-imaging step, the moving mechanismis controlled according to the hair planting pattern data such that the mesh hole to be subjected to hair planting is positioned at the center of the imaging range, and in this state, the cameraperforms imaging.

105 The image acquisition unitperforms the imaging to acquire a pre-image of a mesh targeted for hair planting of the base material J captured before hair planting.

105 11 28 57 341 11 104 In this case as well, similar to the imaging operation described above, the image acquisition unitpositions the cameraby the position switch mechanism, irradiates illumination light by the lighting device, and captures an image of the base material J within the range of the work openingby the camera. The imaging data acquired by this imaging is stored in the data memoryas pre-image data.

101 9 101 283 21 Subsequently, the CPUexecutes a hair planting operation step (step S). In the hair planting operation step, the CPUcontrols the position switch air cylinderto arrange the first capture mechanismat a reference position, and performs a supply operation of the hair for planting M.

101 74 68 71 21 That is, the CPUcauses the hair supply deviceto pull out one hair for planting M and causes the hair holding mechanismto grip it, and further causes the conveying mechanismto place the hair for planting M in standby above the first capture mechanismat the reference position.

101 20 12 14 FIGS.A toB Then, the CPUcontrols the hair planting unitto perform a binding operation of the hair for planting M to the base material J. Since the binding operation has been described with reference to, the details thereof are omitted here.

101 105 11 341 34 11 Subsequently, the CPUagain functions as the image acquisition unit, and after the hair planting operation, performs a post-imaging step in which the cameracaptures the same position as that of the pre-imaging of the base material J within the range of the work openingof the placement plate(step S).

105 The image acquisition unitperforms the imaging to acquire a post-image of the mesh targeted for hair planting of the base material J captured after hair planting.

105 11 28 57 341 11 104 In this case as well, similar to the imaging operation described above, the image acquisition unitpositions the cameraby the position switch mechanism, irradiates illumination light by the lighting device, and captures an image of the base material J within the range of the work openingby the camera. The imaging data acquired by this imaging is stored in the data memoryas post-image data.

105 Subsequently, when the pre-image data and the post-image data before and after the hair planting operation are acquired by the image acquisition unit, a suitability determination process is executed.

18 26 FIGS.A to 26 FIG. The suitability determination process will be described with reference to.is a flow chart showing contents of a suitability determination process.

31 1 2 18 FIG.A 18 FIG.B In the suitability determination process, from the pre-image data and the post-image data, respectively, one mesh targeted for hair planting is trimmed around its periphery and extracted (image clipping step: step S).is a mesh image based on pre-image data (hereinafter, referred to as pre-image G), andis a mesh image based on post-image data (hereinafter, referred to as post-image G). As can be seen by comparing these images, when the hair for planting M is planted into one mesh, the mesh undergoes changes in its shape, posture, position, orientation, and so on, for example due to tension received from the hair for planting M.

1 2 For this reason, it is difficult to accurately obtain the presence or absence, the position, and the like of the hair for planting M that has been planted through a simple comparison process such as taking a difference between the pre-image Gand the post-image G.

101 106 Therefore, the CPUfunctions as a transformation matrix acquisition unitand executes a transformation matrix acquisition step.

106 1 2 33 That is, the transformation matrix acquisition unitexecutes feature point extraction with respect to the pre-image Gand the post-image G(feature point extraction step: step S).

106 1 2 35 The transformation matrix acquisition unitexecutes a matching process between a plurality of feature points extracted from the pre-image Gand a plurality of feature points extracted from the post-image G(matching step: step S).

106 1 2 Subsequently, the transformation matrix acquisition unitselects, from among the numerous pairs of feature points of the pre-image Gand the post-image Gthat have been matched, a plurality of pairs having higher matching scores.

106 1 2 37 In addition, the transformation matrix acquisition unitcalculates, from the position coordinates in the images of the respective selected feature points, a transformation matrix for performing a posture transformation from the pre-image Gto the post-image G(transformation matrix calculation step: step S).

This transformation matrix may be any matrix that performs a transformation mapping from one plane to another. For example, the transformation matrix may be a homography transformation matrix. The homography transformation matrix can, in theory, be obtained if four pairs of feature points are given.

101 107 Subsequently, the CPUfunctions as a difference processing unitand executes a difference step.

107 37 1 11 1 2 39 1 11 1 19 FIG. That is, the difference processing unitperforms a transformation based on the transformation matrix obtained in step Son the data of the pre-image G, and generates a transformed pre-image Gby performing a posture transformation from the pre-image Gto the post-image G(transformed pre-image generation step: step S).shows the pre-image Gand a transformed pre-image Ggenerated from the pre-image G.

11 1 11 The transformed pre-image Gis an image that pseudo-represents a state in which the mesh targeted for hair planting has undergone a change in posture due to tension received from the hair for planting M that has been planted. Since the pre-image G, which serves as the source of the transformation, does not include the hair for planting M, the transformed pre-image Galso naturally does not include the hair for planting M, and is an image including only the mesh that has undergone a change in posture due to the hair for planting M.

107 12 11 2 41 12 11 2 20 FIG. Subsequently, the difference processing unitobtains a difference image Gby taking a difference between the data of the transformed pre-image Gand the data of the post-image G(difference image generation step: step S).shows a difference image Ggenerated by taking a difference between the data of the transformed pre-image Gand the data of the post-image G.

101 108 Subsequently, the CPUfunctions as a hair detection unitand executes a hair detection step.

108 11 13 43 11 13 11 21 FIG. That is, the hair detection unitperforms binarization processing and black dilation processing on the data of the transformed pre-image G, thereby generating a dilated image Gof the mesh (dilated image generation step: step S).shows the transformed pre-image Gand a dilated image Ggenerated from the transformed pre-image G.

108 11 11 11 The hair detection unitfirst performs binarization processing on the data of the transformed pre-image G. Thereby, each pixel constituting the transformed pre-image Gis classified as either black or white by a luminance threshold value. Furthermore, among the respective pixels constituting the binarized transformed pre-image G, pixels that are white are converted into black pixels under certain conditions according to the relationship with surrounding pixels. Thereby, a region in an image where white pixels and black pixels are mixed is unified as black pixels.

21 FIG. 13 As shown in, the dilated image Gconsists of a substantially hexagonal white region at its center representing a mesh hole, six white regions surrounding the mesh hole representing other mesh holes, and black regions forming boundaries between the white regions.

108 13 45 The hair detection unitexecutes a labeling process on each white region in the dilated image G(labeling step: step S).

108 108 0 108 1 6 0 Among the respective labeled white regions, the hair detection unitspecifies a white region having the largest area as the mesh hole targeted for hair planting. Furthermore, the hair detection unitspecifies the six white regions having the next largest areas following the white region Wof the mesh hole targeted for hair planting, and obtains the centroid point positions of the seven white regions. Furthermore, the hair detection unitspecifies the six white areas as white areas Wto Wof “upper”, “upper right”, “lower right”, “lower”, “lower left”, and “upper left”, respectively, from the relative positional relationship of the centroid point positions of the six surrounding white regions with respect to the centroid point position of the white region Wof the mesh hole targeted for hair planting.

13 108 0 1 6 47 Then, for the dilated image G, the hair detection unitdivides, into six groups, respective pixels constituting a contour edge that is a boundary line between the white region Wof the mesh hole targeted for hair planting and the surrounding black region, according to which of the six surrounding white regions Wto Wit is closest (edge division step: step S).

22 FIG. 1 6 is a conceptual diagram in which respective pixels constituting a contour edge are divided into six lines Lto L, with each line represented by a different pattern.

108 1 6 1 6 1 6 49 23 FIG. The hair detection unitobtains an approximate straight line for each of the lines Lto L. For example, as shown in, a least-squares line is calculated from the position coordinates of the pixels constituting each of the lines Lto L, and these are defined as the approximate straight lines LCto LC(approximate straight line acquisition step: step S).

108 1 6 1 6 1 6 0 Then, the hair detection unitgenerates inner contour lines LIto LIand outer contour lines LOto LOby translating the approximate straight lines LCto LCin parallel by the same width toward the centroid point side of the white region Wand toward the opposite side.

1 6 1 6 1 6 15 1 6 1 6 The inner contour lines LIto LIand the outer contour lines LOto LOare acquired by translating the approximate straight lines LCto LCin parallel by a predetermined number of pixels. The number of pixels to be translated in parallel can be arbitrarily set, for example, from the operation panel. However, preferably, the number of pixels corresponds to a width such that the fiber portion around the mesh hole is included between the inner contour lines LIto LIand the outer contour lines LOto LO.

1 1 1 2 6 2 6 2 2 3 3 4 4 5 5 6 6 10 51 A trapezoidal region Tis then formed by the inner contour line LIand the outer contour line LO, which are parallel to each other, and the outer contour lines LOand LOadjacent thereto. Similarly, trapezoidal hair planting position determination regions Tto Tare formed by the inner contour LIand the outer contour LO, the inner contour LIand the outer contour LO, the inner contour LIand the outer contour LO, the inner contour LIand the outer contour LO, and the inner contour LIand the outer contour LO(hair planting) position determination region setting step: step S).

24 FIG. 108 1 6 12 41 108 1 6 12 53 Subsequently, as shown in, the hair detection unitsuperimposes the hair planting position determination regions Tto Ton the difference image Ggenerated in the difference image generation step of S. Then, the hair detection unitcounts, as a score, the number of pixels within each of the hair planting position determination regions Tto Tin the difference image Ghaving a difference value (luminance value) equal to or greater than a specified value (hair planting position determination step: step S).

25 FIG. 1 2 3 4 5 6 An example of the result of the count is shown in. The hair position determination region Tis a region corresponding to the vicinity of the “upper” side of the hexagonal mesh, the hair position determination region Tis a region corresponding to the vicinity of the “upper right” side, the hair position determination region Tis a region corresponding to the vicinity of the “lower right” side, the hair position determination region Tis a region corresponding to the vicinity of the “lower” side, the hair position determination region Tis a region corresponding to the vicinity of the “lower left” side, and the hair position determination region Tis a region corresponding to the vicinity of the “upper left” side.

1 6 Therefore, among the hair planting position determination regions Tto T, the region with the highest score indicates the site that has undergone the greatest visual change before and after the hair planting operation.

25 FIG. 2 2 That is, in the example of, a significant visual change occurs in the upper-right hair planting position determination region Thaving the highest score, and it can be estimated that the hair for planting M is bound to the ‘upper right’ side of the hexagonal mesh corresponding to the hair planting position determination region T.

108 55 Subsequently, the hair detection unitcompares the hair planting pattern data and determines whether the hair for planting M has been bound at the scheduled position of the current mesh targeted for hair planting (data comparison step: step S).

15 FIG. 13 101 15 Subsequently, returning to the flow chart ofshowing the operation control of the hair planting operation, when the suitability determination of step Sis completed, the CPUdetermines the success or failure of the hair planting operation based on the result of the suitability determination (step S).

108 101 That is, if the hair detection unitdetermines that the hair for planting M is not bound at the scheduled position of the current mesh targeted for hair planting, the CPUexecutes a notification process.

15 The notification process may, for example, notify an error externally using the operation panelor other devices such as a lamp, buzzer, or speaker.

9 In addition, different responses may be taken depending on the content of the error. For example, if the hair for planting M is not present at the scheduled position of the mesh and is not erroneously bound at another position, the notification process may return to step Sto retry the hair planting operation.

15 In addition, if the hair for planting M has been bound at a position other than the scheduled position of the mesh, the notification process may notify an error in the binding position with the operation paneland wait for an operator's input for subsequent response. As a subsequent response, the next binding operation may be continued as it is, or the entire hair planting operation may be stopped.

15 101 17 On the other hand, in the determination of the success or failure of the hair planting operation in step S, if it is determined that the hair for planting M has been bound at the scheduled position of the current mesh targeted for hair planting, the CPUdetermines whether the binding of the hair for planting M has been completed for all binding locations in the current unit section K (step S).

7 211 21 If the binding of the hair for planting M has not yet been completed for all binding locations, the processing returns to step S, where the next mesh targeted for hair planting is positioned above the hook needleof the first capture mechanism, and imaged, and the hair planting operation is executed.

101 19 101 51 50 34 On the other hand, if the binding of the hair for planting M has been completed for all binding locations in the current unit section K, the CPUdetermines whether hair planting has been completed for all sections scheduled on the base material J (step S). If hair planting has been completed for all sections, the CPUlifts the clamp plateof the clamp deviceto the lifted position, releases the base material J on the placement plate, and terminates the hair planting operation.

101 21 On the other hand, if hair planting has not been completed for all sections, the CPUexecutes a wiper operation step (step S).

101 411 421 40 621 51 That is, the CPUlowers and retracts each of the rollersandof the feed device, clamps the base material J with each of the auxiliary clamp plates, and retracts the clamp plateto the lifted position.

101 611 613 61 611 612 611 613 511 511 Then, the CPUadvances the wiper memberby the sweeping-out air cylinderof the wiper mechanism, and extends the wiper memberby the telescopic air cylinder. Furthermore, by retracting the wiper memberwith the sweeping-out air cylinder, the hair for planting M inserted in the upper openingis swept rearward and swept out from the upper opening.

64 At this time, the first blower mechanismblows air rearward to suppress the rising of the hair for planting M that has been swept rearward.

101 51 621 Then, the CPUlowers the clamp plateto the weak clamp position and releases the auxiliary clamping of the base material J made by each of the auxiliary clamp plates.

101 23 Subsequently, the CPUexecutes a step of feed control (step S).

101 411 40 412 421 422 That is, the CPUfeeds the base material J in predetermined section units by lifting each of the rollersof the feed deviceand driving the X-axis feed motorto move the base material J in the X-axis direction, or by lifting each of the rollersand driving the Y-axis feed motorto move the base material J in the Y-axis direction.

101 51 After the feed operation to the next section is completed, the CPUlowers the clamp plateto the strong clamp position.

101 3 23 After that, the CPUrepeats steps Sto Sfor all sections and then terminates the hair planting operation.

10 105 101 100 1 2 106 1 2 107 12 11 1 2 108 12 As described above, the hair planting apparatusincludes: the image acquisition unitthat executes an image acquisition step in which the CPUof the control deviceacquires the pre-image Gof a mesh targeted for hair planting of the base material J, captured before hair planting, and the post-image Gthereof captured after hair planting; the transformation matrix acquisition unitthat executes a transformation matrix acquisition step of acquiring a posture transformation matrix of the mesh from the pre-image Gand the post-image G; the difference processing unitthat executes a difference step of acquiring the difference image Gbetween the transformed pre-image G, obtained by transforming the pre-image Gwith the posture transformation matrix, and the post-image G; and the hair detection unitthat executes a hair detection step of specifying the presence or absence or the hair planting position of the hair for planting M with respect to the mesh from the difference image G.

2 1 As a result, it becomes possible, based on the post-image Gof the mesh that has undergone changes in position, shape, posture, or the like due to the binding of the hair for planting M by the hair planting operation, and the pre-image G, to detect the hair for planting M and the binding position of the hair for planting M with maintained accuracy.

106 1 2 In addition, in the transformation matrix acquisition step executed by the transformation matrix acquisition unit, a plurality of feature points of the pre-image Gand a plurality of feature points of the post-image Gare obtained, and the posture transformation matrix is acquired from those that are matched among the feature points. Therefore, an appropriate posture transformation matrix can be readily obtained, enabling the detection of the hair for planting M and the detection of the binding position of the hair for planting M with improved accuracy.

108 1 6 11 12 1 6 In addition, in the hair detection step executed by the hair detection unit, the plurality of hair planting position determination regions Tto Tare set around the mesh hole from the transformed pre-image G, and the hair planting position is specified based on the number of pixels of the difference image Gwithin the plurality of hair planting position determination regions Tto T.

1 2 Accordingly, once the pre-image Gand the post-image Gare obtained, the hair planting position of the hair for planting M after the hair planting operation can be detected with higher accuracy.

Each embodiment of the present invention has been described. However, the present invention is not limited to the above embodiments. For example, in the above embodiments, a component integrally formed by a single member may be replaced with a component divided into a plurality of members and connected or fixed to each other. Additionally, a component formed by connecting a plurality of members may be replaced with a component formed integrally by a single member. In addition, the details described in the embodiments may be appropriately changed without departing from the spirit of the invention.

101 100 10 10 30 20 11 100 For example, the detection method of detecting the hair for planting M planted on the mesh of the base material J, executed by the CPUof the control device, does not necessarily require the hair planting apparatusincluding all of the above-described configurations. For example, the hair planting apparatusmay have a configuration including, as a minimum configuration, the base stageserving as a base support mechanism, the hair planting unit, the cameraserving as an imaging unit, and the control device.

101 10 1 2 In addition, the detection method of detecting the hair for planting M planted on the mesh of the base material J, executed by the CPUdescribed above, may be configured such that an external computer of the hair planting apparatusacquires data of the pre-image Gand the post-image Gthrough communication or the like and executes the method.